Cindy Novak Quality Expo 092209 Presentation

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CINDY NOVAK, CQIA QUALITY EXPO SEPTEMBER 22, 2009 ISO 9001:2008 and Lean Six Sigma in Manufacturing for the Better Good

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ISO 9001:2008 and Lean Six Sigma in Manufacturing for the Better Good

Transcript of Cindy Novak Quality Expo 092209 Presentation

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CINDY NOVAK, CQIAQUALITY EXPO

SEPTEMBER 22, 2009

ISO 9001:2008 and Lean Six Sigma in Manufacturing for

the Better Good

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Agenda

Welcome!What is Lean Six Sigma, ISO 9001:2008The WORMPIIT – The Eight Types of WasteBenefits of Reducing WasteStanding in the CircleHow Reducing Waste Benefits Your Sustainability

ProgramHow ISO 9001:2008 and Lean Six Sigma Work

TogetherCustomer SatisfactionQuestions

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Lean Six Sigma

Why Lean Six Sigma?

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ISO 9001:2008

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The WORMPIIT

The Eight Types of Waste

WaitingOverproductionReworkMotionProcessing Intellect InventoryTransportation

Muda - Japanese for waste

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Eight Types of Waste

Taiichi Ohno, the major contributor to the Toyota Production System, identified seven types of waste. He is considered the grandfather of Lean Manufacturing.

Jeffrey Liker, professor at University of Michigan added the eight, intellect.

Most recently, a ninth type of waste, energy has been discussed.

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WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS

Work in the process has stopped.

Ensure adequate staffing at bottleneck

Cross-train employees so work continues when someone is absent

Make sure supplies are available where needed

Ensure equipment is properly maintained

Maintain safe work environment

The WORMPITT – Waiting

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WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS

Engaging more resources than needed to deliver to your customer.

The worst type of waste because it hides or causes all others, especially inventory.

Establish process maps considering the downstream customer

Create workplace standards for each process

Create signal devices to prevent over processing, i.e. FIFO Lanes

The WORMPITT – Overproduction

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WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS

Any form of scrap, mistakes, errors or corrections resulting from work not being done correctly the first time.

Ensure employees are competent and trained

Create error-proof processes

Create work instructions with the people who perform the work

Create and use checklists

Practice Corrective and Preventive Action

The WORMPIIT - Rework

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WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS

Any extra movement by people that does not add value.

Arrange work areas to shrink movement

Place part trays near employees

Place necessary documents at work stations

Use color coding as much as possible

The WORMPIIT - Motion

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WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS

Having to do anything more than is needed.

Remove unnecessary steps in a process

Consider enterprise resource planning software

Stop unnecessary signoffs and reviews

Use design for manufacturability

The WORMPIIT - Processing

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WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS

Any supply that is in excess / unavailable.

Includes raw materials, WIP or finished goods.

Capital outlay that has not produced income.

Produce only enough to satisfy your downstream customer

Ensure that work arrives at the downstream process when it is required and is not waiting

The WORMPIIT - Inventory

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WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS

Any supply that is in excess / unavailable.

Includes raw materials, WIP or finished goods.

Capital outlay that has not produced income.

Produce only enough to satisfy your downstream customer

Ensure that work arrives at the downstream process when it is required and is not waiting

The WORMPIIT - Inventory

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WHAT IS IT?WHAT IS IT? SOLUTIONSSOLUTIONS

Employees ideas, creativity and abilities are not fully tapped or even considered. Their other abilities are not explored.

Treat your employees as your greatest asset

Establish Quality Circles

Set up Employee Suggestion Systems

Create employee teams to solve process problems

LISTEN, LISTEN………… AND LISTEN!

The WORMPIIT - Intellect

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WHAT IS IT?WHAT IS IT? SOLUTIONSOLUTION

Movement of work or paperwork from one step to the next step in the process.

Make the distance to where something is moved as short as possible.

Consider work cells and co-located teams.

The WORMPIIT - Transportation

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Eight Types of Waste

Benefits of Eliminating WasteSignificantly lower costsHigher profit marginsMore effective, efficient processesExceeding high qualityMore engaged employeesDelighted customers!

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Standing in the Circle

Genchi Genbutsu – Go and see at the actual place of workTaiichi Ohno used this to train new employees

An employee was directed to stand and observe an operation very carefully and identify waste within the operation and the conditions that cause the waste to exist.

If you don’t look, how do you know where the waste is?

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ISO 9001:2008ISO 9001:2008 Lean Six SigmaLean Six Sigma

Plan

Do

Check

Act

DefineMeasureAnalyze ImproveControl

How ISO 9001:2008 and Lean Six Sigma Work Together

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How ISO 9001:2008 and Lean Six Sigma Work Together

With quality objectives required by ISO, LeanSix Sigma provides methods to achieve them:

Prevention of defects at all stages from design through customer service;

Statistical techniques for establishing, controlling and verifying process capability and product

characterization; Investigation of the cause of defects relating to

product, process and quality system; and Continuous improvement of the quality of

products and services.

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Type of Waste Type of Waste SustainabilitySustainability

TransportationInventory

ReworkWaiting

Energy

Reduction in fuel usage

No need to maintain unnecessary real estate

Reduction on scrap and waste sent to landfills

Use people and machines efficiently

Reduction in use of electricity, gas and water

How Reducing Waste Benefits your Sustainability Program

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SustainabilitySustainability Social ResponsibilitySocial Responsibility

Reduction in fuel usage

No need to maintain unnecessary real estate

Reduction on scrap and waste sent to landfills

Use people and machines efficiently

Reduction in use of electricity, gas and water

Lower carbon footprintProtect public landsDedicate a parkReduce Mount

TrashmoreRecycle, reuse, returnMore energy focused on

the final outputConserve energy for the

most productive use

Sustainability complements Social Responsibility

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Customer Satisfaction

Do you have Quality AND Sustainability programs? Do you have an Environmental Policy? If so, have you communicated this to your customers?

Clients expect lower prices today and there is no better way to make that happen than to cut waste. It’s better than cutting jobs!

Align lean and ISO activities with your corporate SRO policy. Let the community know what you are doing.

Include information on your cost-cutting programs on your website. Show results! Your customers may get ideas that help them as well and they will see your commitment as well.

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Resources

American Society for Qualitywww.asq.org

International Organization for Standardizationwww.iso.org

Environmental Protection Agencywww.epa.gov

Getting Business Fit by Gary Kingwww.fitcert.com

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Questions

Questions?

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Thank you!

Remember what Gandhi said,

“You must be the change you want to see.”

Need help? Visit www.isochick.com